REEM WATER HEATER FACTORY

CALORIFIER
200 GALLON
150kW
VERTICAL FLOOR MOUNT

OPERATION & MAINTENANCE

MANUAL

2nd Industrial City, P.O.BOX 149, Riyadh 11383, Kingdom Saudi Arabia
Customer Care: 092 000 8204
info@reem.com.sa
General Installation, Operation & Maintenance Manual

INSTALLATION
1. Foundation must be adequate to ensure that the unit will not settle and cause Pipe
strains or distortion of the shell and should withstand the weight of Calorifier filled
with water.
2. It is necessary to ensure that the ample room exist for withdrawing elements and
clear of shell and also other maintenance works.
3. Tightening of bolts should be evenly distributed over flanges, each bolt being
gradually tighten in succession.
4. Distortion can occur to pipe connecting during transit/handling especially extended
types, if this does happen they can be straightened by insertion of threaded pipe
and pulling square.
5. During heating cycle of water heater, the water expand causing pressure inside the
water heater to increase. The water utility supply may contain a check valve. A
check valve located in the cold water inlet line can cause what is referred to as a
closed water system. A cold water inlet line with no check valve or back flow
prevention device is referred to as an open water system.

As water is heated, it expands the volume and increase in pressure within the
water system. This action is referred to as thermal expansion. In an open water
system, expanding water which exceeds the capacity of the water heater flows
back into the main water supply where the pressure is easily dissipated. If the
pressure in the closed water heater system exceed 150 psi (10 bar). Water will
discharge from the pressure and temperature relief valve. This is the normal
safety function of relief valve and indicates the proper function of the valve.

The result of thermal expansion can create a rapid and dangerous pressure
increase in the water heater and system piping. The rapid pressure increase can
quickly reach the safety setting of the relief valve, causing it to operate during
each heating cycle. Replacing relief valve will not correct the problem. To prevent
this from happening, install a diaphragm- type expansion tank between non-return
valve and tank that is suitable for potable water on the cold water supply line. The
expansion tank must have a minimum capacity of 6liters (1.5 US gallon) for every
190 liters (50 US gallon) for every 190 liters (50 US gallon)of stored water and be
rated for 150 psi (10bar) or working pressure of the water heater. Never lug or
remove the T & P valve. Connect the outlet of the T & P valve to suitable open
drain. The discharge line must be of no smaller than the outlet of the valve and
must pitch downward from the valve to allow complete drainage of the relief valve
and discharge line.
6. This water heater must be installed strictly in accordance with the instructions
enclosed. It is possible that connection to the water heater, or the water heater
itself, may develop leaks. It is therefore imperative that the water heater be
installed so that any leakage of the tank or related water piping is directed to an
adequate drain in such a manner that it cannot damage the building, furniture,
floor covering, and adjacent area, lower floors of the structure or other properties
subject to water damage.

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 7. The installation of unions or flexible copper connectors is recommended on hot and cold water
connection so that the water heater maybe easily disconnected for servicing if necessary. The
hot and connection are clearly marked on all models. Install
a shut off valve in cold water line near the water heater.
8. Electrical Connection
A separate branch circuit with copper conductors, over current protective device and suitable
disconnecting means must be provided by a qualified electrician. The LIMA Calorifers have
been completely wired during assembly. Connecting the electric power supply to the unit
consists simply of connecting power leads to the terminal strips or isolator switch. After
checking the current voltage, phase and amperes.

The exact voltage, phase and amperage requirements for the unit can be determined from the
rating plate affixed to jacket of the unit, submittal or wiring diagram supplied with the unit.

OPERATION

After all installation produces have been completed, all power connections and cold water, hot water
and relief piping joints have been double checked, the unit is ready for operation. As a precaution, it is
strongly suggested that the following start up and shut down procedure be followed.

1. Assure that all manual shut-off valves on cold and hot water lines are closed. (The combination
of electricity and water can cause a very dangerous situation. Assure that all powers have been
shut-off and lock out in an approved manner before attempting any installation or maintenance
procedure).
2. Slowly open the manual shut-off valve on the cold water inlet line, checked to assure no
leakage at the valve or joints during initial filling. Hold the T & P relief valve open to allow air to
release out of the tank. this will speed the filling process. The tank should be filled until the cold
water begins to flow from the open relief valve. As the tank is filling, inspect the matting areas
between the tank and each heating element for leakage.
3. Slowly open the manual shut-off valve on the hot water outlet line. Again check for any sign of
leaks at all joints and valve. Open each hot water faucet slowly to allow air to vent from the
piping. A steady flow of water from the hot water faucet indicates a full water in the tank.
4. The electric water heaters feature fully automatic controls to regulate the water temperature.
The thermostats supplied with the water heater maybe either an immersion or digital with PT
100 sensor. Both types of thermostats use to contact relays to energized heating elements. The
thermostats are factory set to 65°C (140°F) to reduce the risk of scaling. Water temperature
adjustments dial, located on the outside of the lower control panel, to the desired temperature
setting. To set temperature with digital temp. control follow the manual of control. The water
heater is equipped with immersion type high limit control. If for any reason the water
temperature becomes excessive, the high limit will de-energize the heating element circuit.
Once the high limit has bee activated, it must be manually reset by pushing in the red reset
button located on the high limit. The cause of the excessive temperature should be determine
and correct.

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 5. Turn on the Electric Power. As the unit is heating , check the contactors of buzzing or chattering.
If any noise is detected, turn off the power and disassemble contactor. Check and remove any
dust or foreign particles that are detected. Re-assemble the contactor and turn on the power.
6. Each Calorifier is equipped with a pilot lamp that make verifying proper operation on easy
method.
If the pilot lamp is illuminated, the system has adequate water and is functioning within the high
temperature limit.
7. After approximately 30 minutes of operation, shut-off and lock out the power and fill each wire,
connection and fuse clip for excessive temperature. If any connection or clip is found to be
excessively hot, check to assure the integrity of the connection. All connections must be tight for
proper operation.
8. Close and lock the door to the electric control cabinet.
9. Turn on the power supply.
10. After the unit has reached the operating temperature, re-inspect all joints for sign of leakage. In
addition, check the pressure and temperature gauge to verify that the water temperature and
pressure are with in the design specification.

MAINTENANCE

Draining, Flushing, and Sediment Removal

Water may contain fine particles of soil and sand, which settle to the bottom of a tank and thus form a
layer of sediment. It is recommended that the tank be drained and flushed on a regular basis to
remove any sediment that may buildup during operation. Some maintenance and service procedures
require that the heater be drained if being shut down for an extended period of time.

To drain and remove the sediment from the tank:

1. Turn "OFF" Electrical supply.
2. Close the water supply valve.
3. Attach hose to the drain valve and route to an adequate drain.
CAUTION: The water being drained can be extremely hot! The drain hose should be rated
for
at least 90°C (200°F). If the drain hose does not have this rating, open the cold water supply
valve and nearby hot water faucet served by the system until the water flow is no longer hot.
Close the cold water supply valve and resume.
4. Slowly open the drain valve. A nearby hot water faucet must be opened to allow the tank to be
fully drained.
5. Open the cold water supply valve and flush the tank as needed to remove sediment and any
other
foreign matter that may have entered the system. Close the cold water supply valve when clean
water flows.
6. If the heater is to remain empty for an external period of time, it is suggested the drain valve be
left open. When draining is complete, the hose must be removed.
7. Perform any other servicing as required.
8. Close the drain valve, disconnect hose.
9. Follow instructions for operation "Startup" when heater is ready to be put back into service

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Temperature and Pressure (T&P) Relief Valve Check

CAUTION! THE WATER COMING FROM THE VALVE MAYBE EXTREMELY HOT.

Manually operate the temperature and pressure relief valve at least once a year to make sure it is
working properly. To prevent water damage, the valve must be properly connected to a discharge
line which terminates as adequate drain. Stand clear of the outlet (discharge water can be
hot) and slowly lift and release the lever handle on the temperature and pressure relief valve to
allow the valve to operate freely and return to its closed position. If the valve fails to completely
reset and continues to release water, immediately turn "OFF" the power and close the cold water
inlet and call a qualified service technician.

Cathodic Protection
Your water heater has been equipped with one or more anodes that protects the glasslined tank
from corrosion and prolong the life of the water heater. Over time, as the anode(s) works, it
slowly dissolves exposing the steel inner core. Ones the anode(s) is depleted, the tank will start to
corrode, eventually developing a leak. Depending on water conditions, an anode(s) can last from
one to ten years. Many localities treat their water and this can have a significant effect on the life
of your heater. Water conditioning, such as oer-softening, can accelerate the rate at which the
anode(s) is consumed. As with any water heater, it is good practice to check the anode(s)
annually to see if it needs replacing. Do not remove this anode(s) permanently as it will
void any warranties, stated or implied. Rapid depletion or failure to maintain the anode can
leave a heater unprotected and may result in premature failure of the heater due to corrosion and
leaks.

Hot Water Odor

On occasion, and depending on your location, hot water may develop a strong odor. This can be
specially problematic in regions where the water contains sulfur, which results in hot water having
a "rotten egg" odor. If this occurs, drain the system completely, flush thoroughly and refill the
tank . I the water odor or discoloration persist, the anode(s) may need to be changed from
magnesium to one made of aluminum. Aluminum anodes may reduce, but no eliminate, water
odor problems. the water supply system may require special filtration equipment from a water
conditioning company to successful eliminate all water odor problems. In certain cases
chlorinating and flushing of the water heater may be required. Contact your dealer or water
supplier.

Discolored Water
* water rich in iron or other minerals can produce red or brown staining. Heating water
generally
worsen this situation.
* Black water can be an indication of organic contaminates in the water supply. This can be
problematic in areas where the water is obtained from surface or contaminated sources.
Organic
particles can develop bacteria growth. causing potential health hazards.
* Contact your water supplier for proper filtration or water conditioning equipment.
* For bacterial problems contact your local health authority. See also "Hot Water Odor".

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 A sudden appearance of rust-collored water may indicate that the anode(s) has
been
depleted. Once depleted, the anode's inner steel core becomes exposed causing it
to corrode and release iron particles into water. See also "Anode Maintenance".
Lime Scale
Over time all immersion type elements accumulate lime scale on their surfaces.
Various conditions affecting this building up includes:
Volume of hot water used; as the consumption of hot water increases, more
scales results.
Water temperature; the hotter the water the more scale is deposited.
Purity of the water supply.
If it becomes necessary to de lime the elements, use a non-metalic (soft) tool or
scraper to remove the scale taking care not to damage the surface of the element.
Alternatively, use a non-metalic de limed that is approved for use with potable
water to
dissolved the lime scale.
DANGER! Do not use muriatic or hydrochloric acid based de liming solutions.

CIRCUIT DIAGRAM
150Kw, 380-400Vac, 50/60Hz, 3Ph

15

16
BUS BAR

S/S S/S L1+

X0 X0 L1-
15
X1 X1 I1-
X2 X2 FG
X3 X3 L2+
16 X4 X4 L2-
X5 X5 I2-
X6 X6 FG
X7 X7 .

C0 C0 L3+
BUS BAR

Y0 Y0 L3-
Y1 Y1 I3-

DVP04 PT-S
Y2 Y2 FG
. Y3 L4+
C1 Y4 L4-
15 Y3 Y5 I4-
Y4 Y6 FG
Y5 Y7 .

16
24V 24V
RS-485

0V + RS-232 0V
-

A1 C
BUS BAR

15 MIN
16

12

A2 11
15

16

16
15

16

16
15

1 2

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 CALORIFIER
VERTICAL FLOOR MOUNT
200 GALLON

TYPE: COMMERCIAL WATER HEATER

BRAND: LIMA
MODEL: L200GVFM
9 11 CAPACITY: 200 GALLON
2 8
7 MOUNTING: VERTICAL FLOOR MOUNT
6 10
VOLTAGE: 380Vac/400Vac, 50/60Hz, 3Ph
RATED POWER: 150 kW
RATED PRESSURE: 150 psi (10 bar)
PRESSURE TEST: 300 psi (20 bar)
12 TEMP. CUT-OFF: 65°C

1. COLD WATER INLET: 2" BSP

2. HOT WATER OUTLET: 2" BSP
3. RETURN LINE: 2" BSP
4. DRAIN LINE 1" BSP
13 3 5. MANHOLE NB410
6. MAGNESIUM ANODE 1 1/2" BSP
14 7. TEMPERATURE GAUGE 1/2" BSP
5
8. PRESSURE GAUGE 1/2"
9. T&P VALVE 3/4"
10. AIR VENT VALVE 3/4"
15 11. LIFTING HOOK (2)
12. PT100 SENSOR
13. PLC BASED DIGITAL CONTROL PANEL
14. TOUCH SCREEN MONITOR (HMI)
16
15. LOW LEVEL WATER SENSOR
17 16. ELECTRICAL BOX
1
17. THERMOSTATS
18 18. HEATING ELEMENTS
19. MOUNTING RING
20. RING FOOT (ANCHORAGE)
20 4 21. CONCRETE BASE
19

21

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CAUTION
This water heater can deliver scalding temperature water at any faucet in the
system. Be careful whenever using hot water to avoid scalding injury. Certain
appliances, such as dishwashers and automatic clothes washers may require
increased temperature water. By setting the thermostat on this water heater to
obtain increase temperature water required by these appliances, you may create
the potential for scald injury. To protect against injury, you should install an
ASSE approved mixing valve in the water system. This valve will reduce point of
discharge temperature by mixing cold and hot water in branch supply lines. Such
valves are available from the manufacturer of this water heater or local plumbing,
supplier Please consult with a plumbing professional.

DANGER Water temperature over 126°F can cause

severe burns instantly or death from scalds.

Children disabled and elderly are at higher risk

of being scalded.

See Instruction manual before setting

temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available

See manual

APPROXIMATE TIME/TEMPERATURE RELATIONSHIP IN SCALDS

120°F (49°C) More than 5 minutes
125°F (52°C) 1 1/2 to 2 minutes
130°F (54°C) About 30 seconds
135°F (57°C) About 10 seconds
140°F (60°C) Less than 5 seconds
145°F (63°C) Less than 3 seconds
150°F (66°C) About 1 1/2 seconds
155°F (68°C) About 1 second

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NOTE:

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NOTE:

Page 9
 WARRANTY CERTIFICATE
Customer Name: Invoice No: Purchase Date:

Brand: LIMA Model: L200GVFM Serial No.:

Project:

We REEM WATER HEATER FACTORY The MANUFACTURER, of LIMA Brand Water

Heaters do here by state that the water heaters supplied for the above mentioned projects
as per the following particulars are warranted for a period of 5 YEARS starting from date of
purchase against boiler leakage and two years of the parts.

The warranty does not include damage and failure cause by:

* Mishandling, willful damage, and negligence of users.

* Improper installation and/ or if units are installed without adequate shade or
protection on top.
* Inadequate and irregular maintenance of the tank, Heating Element, Mg. Anode, and
safety devices of the unit.
* Use the spare parts which are not genuine and/ or are purchase from unauthorized
source.
* When water conditions are very aggressive and water is not fed through an RO plant
* In case of flood and/ or other natural calamities.

IMPORTANT!
Keep this warranty certificate in safe mode, show this page and invoice
for warranty claim.

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